Embedded Passive Technology Application: Design and Fabrication of an Automotive Engine Controller
Jiming Zhou, John D. Myers · 2005
This paper summarizes Delphi Electronics and Safety's activities of design, fabrication, and testing of an automotive engine controller, which was used to demonstrate the feasibility of embedded passives technology. 3M C-Plyreg capacitive and DuPont ceramic resistive materials were used to make embedded capacitors and resistors respectively. The substrate is a 3.25 times 2.75 inch, eight-layer organic laminate board with minimum of 3 mil line/spacing, flip chips, microvias, embedded resistors and capacitors. 205 of 217 resistors of the controller were embedded with a buried rate of 94%. The resistors were designed for laser trimming with every resistor trimmed to a tolerance of plusmn2%. 13 decoupling caps and 12 filter caps were embedded as well. The substrates were assembled and functionally tested. The completed engine controllers were successfully in a vehicle application at speeds over 100 kilometer/h. Design rules, fabrication processes, technology hurdles, and future considerations are also discussed